DAVE LAWTON PWM KIT INSTRUCTIONS

Parts List

R1 100R/ 2W 1off

R2, R4, R7 100R/ 0.25W 4off

& R8

R5 & R11 10k pot 2off

R6 & R10 47k pot 2off

R13 47R 1off

R14 10k 1off

C1 100uF 1off
C3, C4 & C10 10nF 3off
C8 220nF 1off
C9 100nF 1off
C11 47uF 1off
C12 10uF 1off
C13 1uF 1off

D1 & D9 1N5408 2off

D2-D6 1N4148 5off
D8 12V zener 1off
D7 11V zener 1off

Q1 IRFP240 1off

IC1 & IC2 555 2off

DIL sockets 8 pin 2off

Meter 1off
Terminal Post (Red) 2off
Terminal Post (Black) 2off
4P3W switch 2off
DPDT min toggle 1off
SPST (10A) 1off
Fuse holder 1off
6A fuse 1off
Switch Knob (pointy one) 2off
Pot Knob (round one) 4off
PCB 1off
Box 1off
Blue crimp receptacle connector 4 off
Blue piggy back crimp connector 1 off
3mm x 12mm bolt 4 off
3mm nut 9 off
4mm solder ring terminal 4 off
Insulating washer 1 off
Dave Lawton Kit Instructions V4.0 07/04/010
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Circuit Diagram

Please excuse the symbolisation of the switches, the EagleCad programme doesn’t have any
appropriate devices

The above addition to the original circuit diagram has been found to cure a problem experienced
by some customers when using this PWM. This modification takes the gating side of the circuit
fully ‘out of the loop’ by adding an extra set of contacts and switch to the existing circuit.

The previously crudely modified PCB has now been superceded by a new custom made one to
accommodate all the problems found with these units in the field. The following photo’s show how
things look when installed.

Dave Lawton Kit Instructions V4.0 07/04/010

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This photo shows the original SPDT gating switch changed for a DPDT version allowing the
normally ‘open’ part of the circuit to be bridged and the gating side of the circuit to function as
normal.

Instructions

1. As with any kit first check and identify all components are present. The picture below is of a
prototype board and the currently supplied components may differ.

2. I’m sure most people will be readily able to assemble the PCB. I normally start with the
resistors/ diodes etc and work my way up in terms of component size. Always check diode
and capacitor polarity against the screen print.

3. Next wire up the various switches/ potentiometers. I use lengths of heatshrink to keep
things tidy. Note you do not need to connect up three wires to the potentiometers. Connect
one end of the potentiometer to the track at the potentiometer. I used the trimmer symbol
on the PCB simply because it was convenient.

4. The second picture shows how we lay out the controls in the box we supply and the details
immediately below show the details of the hole you’ll need to cut out to accommodate the
meter.

Note you’ll need to adjust the position of the tab washer on the 3P4W switch to limit the
rotation to just three positions. We wire up Tab A and tabs 1,2 & 3.

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 Enlarge

Dave Lawton Kit Instructions V4.0 07/04/010

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5. We supply a number of crimp connectors and solder ring terminals with the kit. We prefer to
connect to the 4mm input/ output terminals using the 4mm ring terminals, you can equally
solder direct to these if you wish.

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6. The next picture shows the PCB mounting arrangement. This consists of 2off 3mm bolts
secured with 2off nuts each to act as spacers.

7. Finally connect a piece of aluminium sheet (not supplied) to the MOSFET using 1off 3mm
bolt and washer c/w insulating washer. As can be seen from the next picture we fold this
piece of aluminium around and secure the free end using a 3mm bolt secured with a nut
acting as a spacer and then the aluminium strip and then secured with another nut. This
keeps the strip off the plastic to allow better cooling.
Dave Lawton Kit Instructions V4.0 07/04/010
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These are our MkIII set of instructions. If you feel they need adding to in any way please
feel free to contact us at sales@courtiestown.co.uk

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